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INSPECT ROUTING 1. Remove the upper and lower meter panels (refer to Service Manual page 9D-15). 2. Check if the ignition switch lead wire is clamped and routed correctly. Incorrect positions are shown in Figures 1 and 2. Correct routing and clamping is shown in Figures 3 and 4 on page 5. REROUTING 1. Reroute the ignition switch lead wire correctly (Figure 3 and Figure 4). The ignition switch lead wire should not be covered by the other wire harnesses. 2. Turn the handlebars back and forth to verify that the steering operates smoothly and the wiring harness does not become kinked or pinched. 3. Proceed to PUNCH MARK AT VIN on page 8. from the motorcycle (refer to Service Manual page 1H-12). Remove the two black plastic covers to access the cylinder cap mounting bolts (Figure 5). Note: The black plastic covers will not be reused. Secure the mount area (bottom) of the ignition switch in a vise (Figure 6). NOTE: Turn the ignition switch to the OFF position and remove the key from the ignition switch before disassembling the switch. Remove the two “break-off” screws from the ignition switch using the special screwdriver. Set the stepped end of the sleeve on the special screwdriver facing toward the “break-off” screws (Figure 7). Strike the special screwdriver 5 to 7 times with a hammer to produce a deep enough groove on the screw head for the screwdriver to work properly (Figure 6). Pay attention not to hit other parts with the hammer. Turn to remove the “break-off” screws in a counterclockwise direction. If the groove becomes damaged, make another groove at a 90o angle to the original groove. Remove the ignition switch from the vise and hold it upright over the workbench and carefully remove the cylinder cap (Figure 8). NOTE: Pay close attention to the order and orientation of the ignition switch parts during disassembly. REPLACEMENT OF IGNITION SWITCH (Customer Sold Units/Dealer Demo Units- Only If Inspection Shows Incorrect Routing And Unit Has Been Ridden) New Ignition Switch Disassembly 2.

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INSTALLATION 1. Note the left and right areas on frame where the covers will be installed. Using a 50/50 mixture of isopropyl alcohol and water, thoroughly clean the frame tubes surrounding the fuel cell on the left and right sides. Let dry completely. 2. Unlock and open seat. NOTE Loosening the ignition/light switch screw (in the following step) will allow much easier alignment of the ignition/light switch cover and ignition/light switch during installation. 3. See Figure 1. At area inside of frame rail just above the ignition/light switch housing, loosen the ignition/light switch screw just enough to allow the ignition/switch switch to move slightly from side to side and up and down. Do not completely remove screw 4. See Figure 4. Obtain the right side cover bracket (ignition/light switch side) from kit. 5. Remove the strips protecting the adhesive at all of the raised sections on the cover. 1 2 is 02045 1. Ignition/Light Switch Screw 2. Ignition/Light Switch Figure 1. Loosen Ignition Switch Assembly 6. See Figure 2. Carefully align the right side cover between the three frame tubes. Beginning with the left portion of the cover, press the cover between the upper and lower frame tubes until the raised portions of cover (with adhesive) begin to snap into place. While carefully aligning the right portion of the cover, move the ignition/light switch as necessary until centered within hole in cover, then firmly press into place. Adjust ignition/light switch until the switch is centered within cover. Make sure all raised locations (with adhesive) are firmly contacting the upper and lower frame tubes and that cushion rests against front vertical frame tube. 7. See Figure 1. Tighten the ignition switch screw to 6-10 Nm (53-88 in-lbs ) . NOTE The right side (ignition/light) switch cover surface can be damaged by the key fob (from vibration) when the key is in the ignition and the bike is running. You can either remove the key fob so it does not damage the cover surface, or you can install the plastic clear sheet (included in kit) onto the side cover for protection. 8. If desired, perform the following to install the plastic clear cover onto the ignition/light switch cover. a. Obtain the plastic (rhino) sheet and hold up to the switch cover to determine proper orientation and spacing. b. Carefully peel the adhesive backing from the plastic sheet and position onto the cover. Use a wet sponge, and working out from the center, rub out any bubbles or overlapped areas under the sheet. Allow to dry completely.

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The included 3600-SWHA switch harness is intended for use with offroad models that do not come with a Hi/Low beam switch from the factory. The harness is compatable with stock AC lighting electrical systems as well as high output DC electrical systems. 1. Remove the stock numberplate or headlight. Remove the stock kill switch from handlebars and replace with the 3600-SWHA switch. 2. Remove the gas tank. Route the white and black leads from the 3600-SWHA under the tank following the wires from the stock kill switch. Disconnect the stock kill switch bullet and connect the white wire of the 3600-SWHA to the wiring harness. Disconnect the stock kill switch ring terminal and connect the ring terminal of the 3600-SWHA. Fully remove the stock kill switch. Be sure all the wires are safe from being burned or pinched and re-install the gas tank. 3. Disconnect the two female spade terminals from the stock headlight switch (if present). Connect the terminal with the yellow wire to the red power lead from the switch. Connect the white wire to the blue accessory output from the switch. Be sure the clear silicone sleeves are covering the stock plastic housings. 4. Connect the X2 headlight to the switch headlight plug. Note: The stock headlight plug will not be used for the X2 installation, but is still functional for connecting the stock headlight. The stock plug will turn on and off with the new headlight switch, and will be powered in either of the Low or High Beam positions

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CHECKING OF SWITCHES Check the switches for the continuity between the terminals to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, brake switch, lighting switch, etc.) The extreme left column indicates the switch positions and the top line indicates the colors of leads connected with the terminals in the switch component. “C’&-0″ indicates the terminals between which there is a continuity of electricity; i.e., a cl.osed circuit at the respective switch positions. In this chart: “R and Br” and “L/W and L/R” are continuous with the “ON” switch position. “B and B/W” is continuous with the “OFF” switch position. “B and B/W” is continuous with the “LOCK” switch position. “B and B/W” and “R and L/R” are continuous with the “P” switch position. CHECKING SWITCH FOR TERMINAL CONNECTION Before checking the switch, refer to the connection chart as shown above and check for the correct terminal connection (closed circuit) by the color combination. To explain how to check the switch, the main switch is taken for example in the following

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REPAIR PROCEDURE 1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the cen- ter pins in. Remove the two screws. Disconnect the opener cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the under- side of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been per- formed on this unit

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1. Insert the ignition key into the lock cylinder and open the fairing pocket lid by turning the key clockwise. Remove the two trim clips by pushing the center pins in. Remove the two screws. Disconnect the opener cable and remove the right fairing pocket. 2. To access the bank angle sensor, remove the two mounting screws securing the connector holder. Place the holder to the side. 3. To check for the proper screw size, slightly tighten both bank angle sensor screws. If the screws are tight, reassemble the unit and apply the identification mark. If the screws spin in the holes, proceed to Step 4. 4. Using a magnetic screwdriver, remove and discard one of the two 4 mm screws securing the bank angle sensor assembly. Replace with a 5 x 12 mm self-tapping screw (see the PARTS INFORMATION section on page 3 for the proper screw for this repair). Repeat for the other screw. 5. Reinstall the removed parts in the reverse order of removal. IDENTIFICATION Apply a white paint dot in the center of the underside of the right fairing pocket lid as shown. This will indicate that the Safety Recall has been performed on this unit

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Switch Layout – Left The left handlebar switch contains the standard operating controls for the police motor. The horn switch also operates the siren air horn when the ignition is turned “On”. A supplementary switch holder is standard, containing two switch blank plugs A & B. These locations are reserved for options such as Cruise Lights, Radio Rebroadcast, Radio Speaker “off” or other desired optional rocker switches. Siren Switch: The BMW/Code 3 siren is operated by one momentary push button switch, but only when the ignition is “on”. Pressing the button engages the siren into wail tone. Each subsequent press of the button advances to yelp, then hyper-yelp, then back to wail (California models only have wail and yelp). Press and hold to turn-off siren at any time. The siren has been programmed to accept a push of the button similar to clicking a computer mouse. This was done to avoid accidentally activating siren by nudging the button. A quick, clean press or “poke” of the button provides crisp activation. Switch Layout – Right The right handlebar switch contains the standard operating controls for the police motor including starter button. However, the additional switch functions are as follows: (A) Emergency Lights: This three-position switch controls the switching power to all emergency lights. Rocking the switch down to the middle position engages rear channel for the emergency lights (remember switch (C) must be down), rocking switch (A) down further engages front and rear channels – all emergency lights (adding front and side lights). With the switch in this position, rocking switch (C) up will cancel rear lights, but keep front and side lights operating. An LED indicator display can be seen through the back of the right front LED emergency light housing, showing whether the rear or front and rear emergency light channels are switched “on